INSTALLATION MANUAL
Contents
1. 09193 Effectivity 912 Series Edition 1 Rev 0 page 122 May 01 2007 d04060 d04060 BRP Rotax INSTALLATION MANUAL 21 Connections for instrumentation These connections to be established in accordance to certification and or national specifications The certification for connections and connection lines have to be conducted by the aircraft manufacturer to the latest requirements like FAR and EASA For notes regarding the electric rev counter consult the section 17 21 1 Sensor for cylinder head temperature See Fig 4 84 and 85 NOTE A direct reading of the coolant temperature is not provided for The temperature sensor 1 is directly fitted into cylinder head i e a direct temperature reading of the cylinder head material is taken location in the cylinder head of the cylinders 2 and 3 see Fig 4 connection spade terminal 6 3x0 8 to DIN 46247 grounding via engine block graph of sensor resistance over temperature 04868 Axes x axis axis z axis cylinder head mm mm mm 157 0 157 0 0 1200 1000 800 20 40 60 80 100 120 140 CAUTION The graph resistance over temperature has been determined and is effective at the following conditions only ambient temperature 20 C 68 F tolerance 10 Effectivity 912 Series page 127 Editi2. 09187 attachement 2 os point mm Li R1 ose jum te re to ro ta me R2 414 3 71 0 211 0 max usable L3 thread length R3 L4 R4 L5 R5 564 0 1050 277 0 L6 564 0 105 0 7 0 H6 564 0 105 0 7 0 attachment point up to gearbox S N 28986 2 starting from gearbox S N 28987 A WARNING The engine suspension to be designed by the aircraft or fuselage manufacturer such that it will carry safely the maxi mum occurring operational loads without exceeding the max allowable forces and moments on the engine attachment points d04053 Effectivity 912 Series page 34 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL Vertical axis y axis must be square to the longitudinal axis of the aircraft 02455 Tolerated roll deviation of Yaw tolerance 10 see Fig 11 d04053 Effectivity 912 Series Edition 1 Rev 0 page 37 May 01 2007 BRP Powertrain INSTALLATION MANUAL 10 3 General directives for engine suspension Rubber mounts to be used between engine and aircraft frame to neutralize vibrations Damping elements as generally used in the aircraft industry e g LORD are suitable See Fig 12 NOTE The Fig shows rubber mount Lord J 3608 1 resp J 3608 2 NOTE NOTE WARNING WARNING il CAUTION WARNING All elements to balance out vibrations have to be of captive des
3. 0 00 100 LANE lere tates ca teas did Mente 100 EE oq 101 16 3 Data for optional components of air intake system 104 17 Electric SYSTEM 107 17 1 Requirements on circuit Wiring 5a rastro tmn kr mbar teste ined eb 107 17 1 1 Electromagnetic compatibility EMC EMI 108 108 17 3 Technical data and connection the electric components 110 17 31 Integrated generator uio coe recettes ieee 110 17 3 2 Rectifier re ulator 110 17 33 Electronic 112 17 3 4 Ignition switches MAG switch 112 17 3 5 Blectri Starter 114 17 3 6 Starter relay iicet we 115 17 3 7 External alternator optional extra nanna 116 17 3 8 Connection of the electric rev counter tachometer 118 17 3 9 Battery 119 17 3 10 Capacitor option electric fuel 119 17 3 11 Starting equipment at the electronic modules optional extra
4. 08320 In an installation as depicted with the radiator 9 in a higher position than the standard supplied expansion tank a water accumulator 10 has to be fitted instead of the expansion tank Additionallv a suitable expansion tank 1 has to be installed at the highest point of the cooling circuit CAUTION The size and type of radiator should be adequate to transfer thermal energy of approx 25 kW 24 BTU s for ROTAX 912 A F UL or approx 28 kW 26 5 BTU s for ROTAX 912 S ULS at take off power NOTE Assessment data by experience For troublefree operation at good airflow a radiator of at least 500 cm 78 in area has to be used The flow rate of coolant in the cooling system is approx 60 min 16 US gal min at 5800 rpm As reference value for the necessary cooling airflow approx 0 75 m s at full load can be assumed The flow resistance of the coolant in the optional ROTAX radiator is properly designed for the cooling system Check flow rate and cooling capacity if other radiators are used Effectivity 912 Series page 61 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL No provision has been made for attachment of the radiator s on the engine CAUTION Install the radiator without distortion or stressand free of vibrations rubber mounts are recommended At installation of a non original ROTAX radiator take care of sufficient cooling capacity See section 12 7 Effectivity
5. C 1470 F 850 1560 F max 880 C 1616 F at take off readings of EGT taken approx 100 mm 3 93 in from exhaust flange connections The exhaust gas temperatures EGT have to measured at the initial engine installation in an aircraft and must be verified in the course of test flights WARNING The exhaust system has to be designed and built such that the operating temperatures are maintained and the max exhaust gas temperatures will never be exceeded CAUTION The listed engine performance is given at ISA 15 59 F conditions only on engine that is equipped with an unmodified ROTAX tuned exhaust muffler system and air intake box imi Ls yi z dg 2 ku 100 ROTAX 3 93 in 07131 8 Effectivitv 912 Series page 41 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL 11 3 General directives for exhaust system See Fig 15 A exhaust system especially for universal application has been developed by BRP Powertrain Certification to the latest requirements such as EASA has to be conducted by the aircraft manufacturer The following recommendations should help the aircraft manufacturer to plan a suitable exhaust system NOTE These recommendations derive from years of experience and the results achieved are generally very good Acommon transversal muffler serving a
6. INSTALLATION MANUAL FOR ROTAX ENGINE TYPE 912 SERIES Ref No IM 912 ROTAX 912 ULS WITH OPTIONS part no 898642 N WARNING Before starting with engine installation please read the Installation Manual completely as it contains important safety relevant information These technical data and the information embodied therein are the property of BRP Powertrain GmbH amp Co KG Austria acc BGBI 1984 448 and shall not without prior written permission of BRP Powertrain GmbH amp Co KG be disclosed in whole or in part to third parties This legend shall be included on any reproduction of these data in whole or in part The Manual must remain with the engine aircraft in case of sale Copyright 2009 all rights reserved ROTAX is a trade mark of BRP Powertrain GmbH amp Co KG In the following document the short form of BRP Powertrain GmbH amp Co KG BRP Powertrain is used Other product names in this documentation are used purely for ease of identification and may be trademarks of the respective company or owner Approval of translation has been done to best knowledge and judgement in any case the original text in german language is authoritative 004631 BRP Powertrain INSTALLATION MANUAL 16 Air intake system iii a m seen c 99 16 1 Operating limits ee E 99 16 2 Requirements on the air intake system 480 100 16 2 1 Requirements the intake air ducting
7. external vacuum drive for rev counter governor alternator pump hour meter for version 2 for version 3 for version 4 NOTE Conversion of the version 2 4 to version 3 may be accom plished by ROTAX Authorized Distributors or their Service Center 7 2 Standard engine design 4 stroke 4 horizontally opposed spark ignition engine single central camshaft hydraulic tappets push rods OHV liquid cooled cylinder heads ram air cooled cylinders dry sump forced lubrication dual ignition of breakerless capacitor discharge design 2 constant depression carburetors mechanical fuel pumps propdrive via integrated gear box with torsional shock absorber and overload clutch optional on configuration UL2 014 0152 and ULS4 Effectivity 912 Series page 21 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL expansion tank coolant electric starter standard or with extended power output integrated AC generator with external rectifier regulator oil tank external start relay drive of hydraulic governor on version 3 only Auxiliary equipment optional M CAUTION Any equipment not included as part of the standard engine version and thus not a fix component of the engine is not in the volume of supply Components especially developed and tested for this engine are readily available at BRP Powertrain Following auxiliary equipment has been tested on ROTAX
8. 04054 904054 BRP Rotax INSTALLATION MANUAL NOTE The basic requirement for safe operation is that boiling of conventional coolant must be prevented The boiling point of conventional coolant is 120 C 248 F with a 50 50 mixture proportion and a system pressure of 1 2 bar 18 psi 12 3 Coolanttypes In principle 2 different types of coolant are permitted Type 1 Conventional coolant based on ethylene glycol Conventional coolant is recommended as it is commonly available and has a greater thermal heat transfer capability Its limitation is its lower boiling point Conventional coolant should be used with a mixture of 50 concentrate and 50 water NOTE Some conventional coolant is available pre mixed by the manufacturer In this case do not mix with water follow the manufacturers instructions on the container Conventional coolant with a rate of 5096 water cannot boil ata temperature below 120 C 248 F at a pressure of 1 2 bar 18 psi Thus the coolant temperature limit is at max 120 C 248 F Permanent monitoring of coolant temperature and cylinder head temperature is necessary Type 2 Waterless coolant based on propylene glycol Waterless coolant is recommended if the design of the aircraft can not maintain the coolant temperature limit Waterless coolant has a very high boiling point that prevents coolant loss due to boiling over vapor loss but not to prevent detonation which can
9. 25 V is necessary 17 3 11 Easy start function on the electronic module optional See Fig 67 and 79 1 In order to use the easy start function the relevant connections to the starter relays and ignition switch need to be made The start function can be used for aircraft which have an engine start problem in cold conditions NOTE In addition also a modified fly wheel hub is offered which aids improved starting bl blau blue br braun brown bl sw ge gelb yellow gn gr n green sw schwarz black ws weiB white S or orange orange Fig 79 1 viol violett violet 00219 5 Effectivity 912 Series page 119 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL NOTES d04059 Effectivity 912 Series page 120 Edition 1 Rev 0 May 01 2007 904641 Effectivity 912 Series Edition 1 Rev 1 BRP Powertrain INSTALLATION MANUAL 18 Propeller drive The propeller in tractor or pusher arrangement has to be fitted on the propeller flange in accordance to current certification As required utilize one of the three possible pitch circle diameters P C D on the flange Certification of the propeller sizing and arrangement to the latest requirement such as FAR or EASA has to be conducted by the aircraft manufacturer A WARNING Never run the engine without a propeller installed as engine would 18 1 suffer severe damage by overspeeding Never fit propeller directly on crankshaft Techn
10. Example EVANS NPG See Fig 22 7 Warning sticker 2 Radiator cap rm ZR 3 Opening pressure information of radiator cap C3 Lag 12 4 Check cooling system Efficiency of the cooling system For a measurement of the cooling system the maximum values for coolant exit temperature and cylinder head temperature must be found According to the current specifications Effectivity 912 Series page 50 Edition 1 Rev 1 May 01 2009 d04635 104635 BRP Powertrain INSTALLATION MANUAL 12 4 1 Measurement of cvlinder head temperature and coolant exit Effectivitv 912 Series Edition 1 Rev 1 temperature There are two temperature sensors 1 see Fig 23 on the cylinder 2 and 3 for measuring the cylinder head temperature During flight test the place with the highest cylinder head temperature must be found this can vary with different engine installation cowling or free installation tractor or pusher fight speed etc The measuring of the coolant exit temperature is performed using a separate sensor which has to be installed in the line between expan sion tank 1 and radiator inlet 2 09152 The sensor may be installed in a TEE inline with the fluid hose or the expansion tank may be modified to attach the sensor not supplied by BRP Powertrain A WARNING restrict the coolant flow with the sensor devise CAUTION _ It is possible to receive a misleading reading when m
11. 119 18 Propeller drive entt 121 NCC II ANS ii 121 19 Vacuum m 123 19 1 Technical data 123 20 Hydraulic governor for constant speed propeller 125 20 1 Technical data ts cs 125 21 Connections for instrumentation sense 127 21 1 Sensor tor cylinder head temperature ssncscrsstometoueedeiensenstnetts 127 21 2 Sensor for oil temperature oeste tea tae BR 128 21 3 Oil pressure nano eee 129 21 4 Mechanical rev counter 130 21 5 Monitoring of the intake manifold pressure 131 21 6 Air temperature in the airbox optional 132 22 Preparations for trial run of engine 133 Effectivity 912 Series page 5 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL NOTES 904050 Effectivity 912 Series Edition 1 Rev 0 page 6 May 01 2007 BRP Powertrain INSTALLATION MANUAL 3 Preface In this Manual the installation of all ROTAX 912 Series engines is described NOTE ROTAX 912 Series includes 912 A 912 F 912 S 912 UL 912 ULS and 912 ULSFR Before starting with the engine installation read this Installation Manual carefully The Manual will provide you with basic information on correct engine installation a requirement for safe engine operati
12. 912 Series page 62 Edition 1 Rev 0 May 01 2007 04054 BRP Rotax INSTALLATION MANUAL 12 10 Coolant capacity 4 cylinder heads 560 cm 34 1 in water DID 28e 100 cm 6 10 in expansion tank 250 cm 15 2 in 2 m coolant hose 18 mm 71 in inside dia 500 30 5 in total coolant quantity in engine approx 1 51 0 4 gal US 12 11 Cooling air ducting Contrary to the cylinder heads the cylinders are ram air cooled Plan cooling air ducting according to installation requirement A WARNING cooling air ducting has to be designed and built such that the operating temperatures are kept within the specified limits and maximum values are not exceeded This must also be warranted at hot day conditions Max permissible cylinder wall temperature on cylinder 2 200 C 392 F see Fig 36 Schraube screw M5 02050 d04054 Effectivity 912 Series page 63 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL 12 11 1 General directives for ducting of the cooling air See Fig 2 3 4 For front installation in a closed fuselage ducting of cooling air to the cylinders is recommended In this case a costly horizontal partitioning baffles can be avoided NOTE The engine remains in this case completely on the warm side of the engine compartment and is very well accessible In
13. A Wires from the ignition switches connect to the electronic module see Fig 71 d04059 Effectivity 912 Series page 112 Edition 1 Rev 0 May 01 2007 d04059 BRP Rotax INSTALLATION MANUAL Requirements for correct operation of the integrated rectifier regulator the rectifier regulator has to be protected by a slow blowing fuse or circuit breaker Fuse or circuit breaker rating must be determined by load wire size and length cross section of the main circuit at least 4 mm 10 AWG capacitor Fig 67 Pos 14 of at least 22 000 uF 25 V is necessary to flatten voltage current M CAUTION The current over speed graph has been determined and is effective only at the following conditions ambient temperature 20 C 68 F voltage permanent 13 5 V tolerance 5 NOTE The speed of the auxiliary generator is 1 24 or 1 32 times crankshaft speed or 3 times the prop speed 1 min rpm n Propeller rpm propeller 00547 2000 3000 4000 5000 6000 7000 8000 Dione ator z Effectivity 912 Series page 117 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL 17 3 8 Connection of the electric rev counter tachometer See Fig 67 79 Feeding wiring to electric rev counter on left side of ignition housing connections 2 flexible cables 0 5 mm white yellow blue yellow in insulation wrap length approx 600
14. CAUTION Utilize max slip on length Secure hoses with suitable screw clamps or crimp hose connection on fuel pump 2 supplied with fire sleeved lines See fig 57 Fuel intake connection 12 fitting 15 9 16 18 UNF AN 6 Tightening torque 15 Nm 135 in Ib Fuel outlet connection 13 hose nipple 14 3 4 DIN 7642 Effectivity 912 Series page 88 Edition 1 Rev 0 May 01 2007 d04056 104638 15 Carburetor See Fig 58 BRP Powertrain INSTALLATION MANUAL The carburetors on the standard engine are alreadv attached bv a flexible flange and connecting hoses on the airbox connections of the Bowden cable for pre heating choke and throttle have to be established It is recommended to make the adjustment of the Bowden cable after engine installation has been completed to ensure exact final adjustment A WARNING The carburetor flange assembly has to carry the weight of the carburetor and intake svstem Ensure that the screw of the clamp is positioned on the underside as supplied and the gap between the clamp plates is 8 mm 31 in 15 1 Requirements on the carburetor See Fig 59 The carburetors are positioned above the exhaust sockets Below the carburetors one each drip tray 1 with a draining connection 2 is fitted which serves as a heat shield as well CAUTION A WARNING The float chamber venting lines 3 lines have to be routed into a ram air and vacuum
15. and LOCTITE 243 mA 25 Fig 89 o 2 4 6 8 a 08442 page 129 May 01 2009 BRP Powertrain INSTALLATION MANUAL As the instruments need a separate power supply and a different design for the electrical oil pressure sensor the resistance type instrument type VDO which was supplied by BRP Powertrain up to now is not suitable anymore Suitable instruments are offered by various instrument manufacturers e g ROAD or Aviasport A WARNING Certification to the latest requirements such as FAR of EASA has to be conducted by the aircraft manufacturer 21 4 Mechanical rev counter tach drive See Fig 90 and 91 location ignition housing 1 direction of rotation of the rev counter shaft 2 clockwise see figure below position of rev counter drive installation dimensions see figures above Axes point of x yaxis zaxis engagement mm mm 16 063in lt e 26 2 reduction ratio i 41 1 4 of engine speed d04641 Effectivity 912 Series page 130 May 01 2009 Edition 1 Rev 1 BRP Powertrain INSTALLATION MANUAL 21 5 Monitoring of the intake manifold pressure See Fig 92 Connection nipple 1 to measure manifold pressure outside dia B 6 mm 1 4 slip on length
16. free zone or into the airbox according to the requirements and release of BRP Powertrain See section 16 These lines must not be routed into the slipstream or down the firewall Pressure differences between intake pressure and pressure in the carburetor chambers may lead to engine malfunction due to incorrect fuel supply In the area of the float chamber the temperature limit of the fuel must not be exceeded If necessary install additional insulation or heat shields Certi fication to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer Effectivity 912 Series Edition 1 Rev 1 page 91 May 01 2009 BRP Powertrain INSTALLATION MANUAL 15 1 1 Drainage piping on airbox and drip trays WARNING Connect drainage lines well otherwise emerging fuel from a possible leakage could drip onto the exhaust system RISK OF FIRE The lines have to be routed such that in case of a damage the surplus fuel is drained off suitably Route the lines without kinks and avoid tight bends Route the lines with a continuous decline The lines have to be protected against any kind of blockage e g by formation of ice CAUTION With closed or blocked leakage piping fuel could end up on exhaust system RISK OF FIRE CAUTION float chamber venting lines 3 lines have to be routed into a ram air and vacuum free zone or into the airbox according to the requirements and release o
17. kink pinch or otherwise improperly stress the wiring harness Use proper routing clamping and strain relief on wiring harnesses 17 1 1 Electromagnetic compatibility Electromagnetic interference EMI and lightning The engine complies with the EMI and lightning requirements per DO 160C sections 18 20 22 as noted in the following paragraphs Emission Conducted RF Interference Narrowband and broadband emissions meet RTCA DO160C Section 21 1 Cat B AZ exceptin the frequency range of 150kHz 2MHz where emissions up to 20dB higher than allowable limits Radiated RF Interference Narrowband and broadband emissions meet RTCA DO160C Section 21 Fig 21 6 and 21 7 Cat B except in the frequency range of 190kHz 2MHz where emission are up to 35dB higher than allowable limits WARNING Consult the manufacturer if further interpretation is needed These exceedances do not affect engine operation 17 2 Wiring diagram See Fig 67 Legend to wiring diagram Fig 67 Items 1 9 24 25 are included in the standard volume of supply of the engine Items 10 14 are available as accessory Items 15 23 can t be supplied by BRP Powertrain A WARNING certification of items components which are not included 1 2 3 4 5 6 7 8 9 10 12 13 in the standard volume of supply of engine has to be conducted by the aircraft manufacturer to the latest requirements such as FAR or EASA 2 electronic modu
18. mm 24 in starting from ignition housing CAUTION BRP Powertrain developed especially for this applica tion a non certified electric rev counter Certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer See also Sl 13 1996 latest issue The graphs depicting output signals have been deter mined and are effective only at the following condi tions Ambient temperature 20 C 68 F Tolerance 5 The pick up for the rev counter generates one pulse per revolution Pulse shape and pulse voltage as per recordings oscillogram speed 500 rpm load 100 2 speed 500 rpm load 100 kQ V 15 10 E 1 Umdr rev 5 CV 1 rev Cv 360 Fig 79 a 00219 speed 6000 rpm load 100 speed 6000 rpm load 100 V V 100 50 0 50 1 rev 360 100 150 1 rev V 360 Effectivity 912 Series Edition 1 Rev 1 page 118 May 01 2009 104640 BRP Powertrain INSTALLATION MANUAL 17 3 9 Battery See Fig 67 CAUTION Towarrantreliable engine start use a battery of atleast 16 Ah capacity 17 3 10 Capacitor Option electrical fuel pump See Fig 67 CAUTION warrant reliable operation of the electrical fuel pump the use of capacitor of at least 22 000 UF
19. special cases a separate cold air supply to the air intake filters has to be provided BRP Powertrain has developed especially for this application a non certified cooling air ducting A WARNING Certification to the latest requirements to FAR or EASA has to be conducted by the aircraft manufac turer The following recommendations should assist the aircraft manu facturer at the planning of a suitable cooling air ducting The cooling air ducting to be adequate to transfer thermal energy of approx 6 kW 5 7 BTU s at take off power required cross section of air duct at least 100 cm 16 in material glass fibre reinforced plastic or heat resistant non inflammable material attachment formlocking on engine case and cylinders NOTE In case formlocking attachment won t be adequate additional attachment is possible on two tapped lugs 8 on top side of engine d04635 Effectivity 912 Series page 64 Edition 1 Rev 1 May 01 2009 104636 BRP Powertrain INSTALLATION MANUAL 13 3 Checking of the lubrication svstem To control the proper function of the lubrication svstem the following readings have to be taken on the running engine as part of the test qualification procedure NOTE The required pressure gauges and connection parts are not included the BRP Powertrain engine delivery 13 3 1 Measuring of the vacuum Measuring of vacuum in the oil suction line 1 line from oil tank to o
20. 00 105 05 01 2009 13 05 01 2009 54 200 106 05 01 2009 14 05 01 200 55 2009 15 05 01 200 56 200 17 107 05 01 2007 16 05 01 200 57 200 108 05 01 2009 58 200 109 05 01 2009 5 17 05 01 2009 59 200 110 05012007 18 05 01 200 60 200 111 05012009 61 2006 112 05 01 2007 6 19 05 01 2009 62 200 113 05 01 2007 20 05 01 200 63 200 114 05 01 2007 64 2004 115 05 01 2007 7 21 05 01 200 65 200 116 05 01 2007 22 05 01 2009 66 200 117 05 01 2007 23 05 01 200 118 05 01 2009 24 05012007 43 67 200 119 05012009 25 0501200 68 200 120 05012007 26 0501200 T 69 bs 01 2004 70 D5 01 200 18 121 05012009 8 27 0501200 71 05 01 200 122 0501 2007 28 05 01 200 72 200 29 05 01 200 73 200 19 123 05 01 2007 30 05 01 200 T 74 200d 124 05 01 2007 75 200 9 31 05 01 2009 76 200 20 125 05 01 2007 32 05 01 200 77 2006 126 05012007 10 33 05 01 2009 2 21 127 0501 2007 34 05 01 200 80 200 128 05012009 35 0501200 81 200 129 05012009 36 05 01 200 82 200 130 05012009 37 0501200 131 05 01 2009 38 05012004 44 83 200 132 05 01 2009 84 200 133 05 01 2007 85 200 134 05 01 2007 86 200 87 2009 88 200 89 200 90 200 Effectivity 912 Series page 17 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 1 Rev 0 page 18 May 01 2007 04051 BRP Powertrain INSTALLATION MANUAL 6 Table of amendments Approval The technical content is approved under the authority of DOA Nr EASA 2
21. 1J 048 00568 chapter page date of remark for date of signature change approval from authorities inclusion 0 JO 25 all 05 01 2007 DOA 1 0 2 05 01 2009 DOA 1 5 05 01 2009 DOA 3 9 05 01 2009 DOA 4 11 12 13 05 01 2009 DOA 5 17 05 01 2009 DOA 6 19 05 01 2009 DOA 7 22 05 01 2009 DOA 9 31 05 01 2009 DOA 10 33 38 05 01 2009 DOA 11 42 05 01 2009 DOA 12 47 50 51 55 0501 2009 61 64 05 01 2009 DOA 13 69 74 77 05 01 2009 DOA 14 87 05 01 2009 DOA 15 91 92 93 05 01 2009 DOA 16 99 100 102 103 05 01 2009 DOA 105 106 05 01 2009 DOA 17 108 109 111 105012009 DOA 118 119 05 01 2009 DOA 18 121 05 01 2009 DOA 21 128 129 130 05 01 2009 DOA 131 132 05 01 2009 DOA Effectivity 912 Series page 19 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 1 Rev 0 page 20 May 01 2007 04051 904052 BRP Rotax INSTALLATION MANUAL 7 Description of design 7 1 Designation of type Basic type e g ROTAX 912 version 2 version 2 with prop flange for fix pitch propeller version 3 with prop flange with drive of hydraulic governor for constant speed propeller version 4 with prop flange for fix pitch propeller but prepared for retro fit of hydraulic governor for constant speed prop not supplied by manufacturer anymore Optional extras to the above stated basic type
22. 23 m3 min 220 cfm 16 2 3 Airbox See Fig 64 volume at least 2 5 66 US gal outline dimension see Fig 64 The airbox is furnished with 2 drain holes 1 at the lowest position possible The holes are necessary to drain fuel from flooding float chambers caused by badly closing float valve Drainage lines A WARNING Connect draining lines without fail otherwise emerg ing fuel could drip onto the exhaust system RISK OF FIRE The lines have to be routed such that in case of damage the surplus fuel is drained away suitably Route the lines without kinks and avoid narrow bends Route the lines with a continuous decline The lines have to be protected against any kind of blockage e g by formation of ice CAUTION With closed or blocked drainage bores fuel could flow into combustion chamber possibly ruining the engine by hydraulic lock or emerging fuel could drip onto the exhaust system RISK OF FIRE Effectivity 912 Series page 101 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL CAUTION drainage lines 1 lines have to be routed into a ram air and vacuum free or into the airbox according to the requirements and release of BRP Powertrain See also section 15 These lines must not be routed into the slipstream If the drainage lines of the airbox are connected with the drainge lines of the drip trays or the carburetors by a T piece these lines must not be routed
23. 3 Ib max 8 N 1 8 Ib limit load 20 N 4 5 Ib NOTE Throttle opens by spring Effectivity 912 Series page 94 Edition 1 Rev 0 May 01 2007 d04057 104639 BRP Powertrain INSTALLATION MANUAL 16 Air intake system See Fig 64 The intake system is determined essentially by the demands of engine and of the acceptable noise emission on the intake side An airbox be supplied by BRP Powertrain as an option Performance data as specified and limits of operation can only be warranted by employment of the genuine ROTAX airbox CAUTION performance is given at ISA 15 59 F condition only Engine is equipped with unchanged ROTAX tuned exhaust muffler system and air intake box If it will be necessary to use a different airbox or a modified genuine ROTAX airbox for reasons of installation the certification to the latest requirements such as FAR and EASA has to be conducted by the aircraft manufacturer NOTE If an airbox or genuine ROTAX airbox is retrofitted ata ROTAX 912 A F UL Series a change in the carb jetting is required See Illustrated Parts Catalog 912 914 chapter 22 and or SB 912 044 Use of the ROTAX supplied airbox latest issue 16 1 Operating limits Fuel mixture distribution Low cold air temperature in the airbox is favourable for engine performance and to reduce knocking tendency at combustion The certification to the latest requirements such as FAR and EASA ha
24. LLATION MANUAL Feasible position and location of the oil cooler See Fig 50 On principle the oil cooler 5 has to be installed below the oil pump of the engine CAUTION Theoilcooler has to be installed with connections upwards i e in positive direction on z axis This will prevent an unintentional draining of the oil cooler at longer engine stop CAUTION This will prevent an unintentional draining of the oil cooler at longer engine stop A WARNING The oil cooler has to be planned and installed such that the specified operating temperatures are maintained and the max values are neither exceeded nor fall below This state has to be warranted for hot day conditions too If need be take appropriate measures like changing size of cooler partial covering of cooler etc General notes on oil cooler BRP Powertrain offers for this engine oil cooler see Illustrated Parts Catalog latest issue A WARNING Certification of this cooler to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufac turer CAUTION The oil cooler has to be designed to dissipate approx 8 kW 7 58 BTU s heat energy at take off power NOTE From years of experience we recommend an oil cooler size of at least 160 cm 25 ir provided that air flow is adequate CAUTION The cooler must not restrict oil flow Test system as per sec 13 3 Filling capacity Oil quantity without oil coole
25. May 01 2009 BRP Rotax INSTALLATION MANUAL 16 3 Data for optional components of air intake system air filter See Fig 65 weight see section 8 d04058 Effectivity 912 Series Edition 1 Rev 0 page 104 May 01 2007 BRP Powertrain INSTALLATION MANUAL airbox configuration part no 867756 See Fig 66 weight see section 8 107 4 22 in 322 5 12 7 in 456 17 96 in _ 180 709 360 14 18 in 90 3 55 in 60 2 37 410 16 14 in 09174 Effectivity 912 Series page 105 Edition 1 Rev 1 May 01 2009 BRP Powertrain INSTALLATION MANUAL airbox new version part no 667355 in comparison to the old version See Fig 66 1 weight see section 8 Alte Ausf hrung TNr 867756 Neue Ausf hrung TNr 667355 Old Version i New Version 21 Aenderungen modification 45 128 5 04 in T 4 5 E 3 8 b X T 180 7 09 6 g 104639 page 106 Effectivitv 912 Series Mav 01 2009 Edition 1 Rev 1 d04059 BRP Rotax INSTALLATION MANUAL 17 Electric system See Fig 67 The engine is supplied with the wiring completed and ready to operate Only the following connections to the aircraft have to be established int
26. ULS S A 135 275 F Permanent monitoring of cylinder head temperature is necessary Additional monitoring of the actual coolant temperature is possible but not necessary for waterless coolant WARNING The cooling system has to be designed so that operating temperatures will not be more than the maximum values Monitoring the cylinder head temperature is important to control the engine cooling and prevents detonation within the operating limits It is also necessary to design the cooling circuit so that under no conditions the coolant does get near its boiling point because a subsequent loss of coolant can quickly cause the engine to overheat The boiling point of the coolant is influenced mainly by the type of coolant the proportion of the mixture percentage water rate the system pressure opening pressure of radiator cap Correlation between coolant temperature and cylinder head temperature There is in principle a regular relationship between coolant temperature and cylinder head temperature The coolant transfers some of the combustion heat to the radiator Thus the coolant temperature is usually lower than the cylinder head temperature But the temperature difference between coolant and cylinder head is not constant and can vary with different engine installation cowling or free installation tractor or pusher flight speed etc Effectivity 912 Series page 48 Edition 1 Rev 0 May 01 2007
27. arious openings must not be removed see section of protective covering engine has to be stored in a suitable place at min 40 C 40 F and max 80 C 176 F If the engine is stored for a period longer than 12 month perform every 3 months the tasks given in the current valid Maintenance Manual section Preservation of a new engine Effectivity 912 Series page 31 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL 9 4 Protective covering All openings are protected against ingress of contamination and dampness It is recommended not to remove these plugs until installation of the specific feed line NOTE If the engine will be sent to the manufacturer or distributor reuse transport equipment and replug openings List of protective covering exhaust socket ne 1x cone plug connection for manifold pressure 1x cap ADO 2x fuel pump inlet ans 1x cap connection for fuel return 1x plug connection for fuel pressure 1x plug oil supply and oil discharge 1x each cap supply and discharge of coolant 1x each cone plug propshaft on version 3 uscite eR 1x disk plug carburetor if not equipped with an airbox 2x disk plug A WARNING Protective covering to be utilized for transport and at engine insta
28. ay be needed to fully complete or understand an instruction revision bar outside of page margin indicates a change to text or graphic 4 2 Safety information AWARNING certified technicians authorized by the local airworthiness authorities and trained on this product are qualified to work on these engines A WARNING Never fly the aircraft equipped with this engine at locations airspeeds altitudes of other circumstances from which a suc cessful no power landing cannot be made after sudden engine stoppage Unless correctly equipped to provide enough electrical power for night VFR according latest requirement as ASTM the ROTAX 912 UL ULS is restricted to DAY VFR only Effectivity 912 Series page 11 Edition 1 Rev 1 May 01 2009 BRP Powertrain INSTALLATION MANUAL This engine is not suitable for acrobatics inverted flight etc This engine shall notbe used on rotor wing aircraft helicopters or any similar aircraft It should be clearly understood that the choice selection and use of this particular engine on any aircraft is at the sole discretion and responsibility of the aircraft manufacturer assembler and owner user Duetothe varying designs equipment and types of aircraft BRP Powertrain makes no warranty or representation on the suitability of its engine s use on any particular aircraft Further BRP Powertrain makes no warranty representation of this engine s suita
29. bility with any other part component or system which may be selected by the aircraft manufacturer assembler or user for aircraft application Unless in a run up area never run the engine with the propeller turning while on the ground Do not operate engine if bystanders are close To prevent unauthorized use never leave the aircraft unattended with the engine running Toeliminate possible injury or damage ensure that any loose equipment or tools are properly secured before starting the engine When in storage protect the engine and fuel system from contamination and exposure Never operate the engine and gearbox without sufficient quantities of lubricating oil Never exceed maximum rated r p m and allow the engine to cool at idle for several minutes before turning off the engine The engine should only be installed and placed into operation by persons familiar with the use of the engine and informed with regard to possible hazards Never run the engine without a propeller as this will inevitably cause engine damage and present a hazard of explosion Propeller and its attachment with a moment of inertia in excess of the specified value must not be used and releases engine manufacturer from any liability Improper engine installation and use of unsuitable piping for fuel cooling and lubrication system releases engine manufacturer from any liability Unauthorized modifications of engine or aircraft wil
30. down the firewall drainage lines of the airbox spearately are allowed Pressure differences between intake pressure and pressure in the carburetor chambers may lead to engine malfunction due to incorrect fuel supply Connecting nipple 1 of drainage line outside dia 6 mm 1 4 Slip on length max 17 mm 11 16 Provide connection to take readings of manifold pressure 2 Provide connections for temperature sensor 3 Outside diameter 6 mm 24 in Slip on length 17 mm 67 in Connecting nipple 1 of float chamber venting lines outside dia 6 mm 1 4 slip on 1 max 17 mm 11 16 B CAUTION Utilize the complete slip on length Secure hoses by suitable screw clamps or by crimp connection CAUTION Ifthe engine has been installed without employment of the optional ROTAX engine frame which includes also support of the airbox than provide an appropriately support 5 for the airbox Effectivity 912 Series page 102 Edition 1 Rev 1 May 01 2009 d04639 BRP Powertrain INSTALLATION MANUAL NOTE Make sure that the air intake tubes of the airbox for fresh air and preheated air are connected correctly see Fig 64 NOTE Fig 64 shows the genuine ROTAX airbox 8 Effectivitv 912 Series page 103 Edition 1 Rev 1
31. e Overhaul Manual Illustrated Parts Catalog IPC Alert Service Bulletin Service Bulletins Service Informations Service Letter are based on data and experience that are considered applicable for profession als under normal conditions The rapid technical progress and variations of installation might render present laws and regulations inapplicable or inadequate The illustrations in this Manual are mere sketches and show a typical arrange ment They may not represent the actual part in all its details but depict parts of the same or similar function Therefore deduction of dimensions or other details from illustrations is not permitted Effectivity 912 Series page 14 Edition 1 Rev 0 May 01 2007 d04051 104632 BRP Powertrain INSTALLATION MANUAL 5 Listof the effective pages 00567 chapter page date chapter page date chapter page date 0 1 0501200 11 39 0501200 15 91 05 01 2009 2 05 01 2009 40 05 01 200 92 05 01 2009 41 05 01 200 93 05 01 2009 1 3 05 01 200 42 05 01 2004 94 05 01 2007 4 05 01 200 43 05 01 200 95 05 01 2007 5 05 01 2009 44 05 01 200 96 05 01 2007 6 05 01 200 45 05 01 200 97 05 01 2007 46 05 01 200 98 05 01 2007 2 7 05 01 200 8 05 01 200 12 47 2004 16 99 05 01 2009 48 200 100 05 01 2009 3 9 05 01 2009 49 200 101 05012007 10 0501200 50 2009 102 05 01 2009 51 2009 103 05 01 2009 4 11 05 01 2009 52 200 104 05 01 2007 12 05 01 2009 53 2
32. easuring fluid temperatures If fluid volume is lost and the probe is not fully submerged in the fluid the display could show a lower temperature than actual measuring air temperature instead of fluid tempera ture page 51 May 01 2009 BRP Rotax INSTALLATION MANUAL 12 5 Determination of operating limits Coolant and necessary modifica tion on radiator installation Depending on the achieved maximum values of the cylinder head temperature and the coolant temperature following action are necessary 08358 maximum values for coolant used for tests Coolant Cylinder head Conventional coolant Waterless coolant temperature temperature less than d for 135 C 275 F isplaying coolant temperature is necessary Modifications to the instruments or limit not necessary less than a 135 275 F 150 2 300 F less than 120 C 248 F 150 C 300 F b more than 120 C 248 F Cooling capacity too low th T es i F Check of the installation necessary Cooling capacity too low Check op 2 150 C gt 300 F c of the installation necessary more than c 135 275 F 150 300 F less than 120 C 248 F more than 120 C 248 F 9 engine type 912 ULS S 2 engine type 912 UL A F a Maximum cylinder head temperature is below operating limit Operating with waterless coolant is permissible without modification to the installa
33. egrated generator external rectifier regulator electronic modules electric starter start relay items conditional for operation like circuit breakers ON OFF switches control lamps relays instrumentation and capacitors Optional extras external alternator as option if the output of the integrated generator is inadequate electric rev counter accessory consumer battery 17 1 Requirements on circuit wiring CAUTION The connections have to be completed by the aircraft manu facturer in accordance to effective certification and wiring diagram Fig 67 The electromagnetic compatibility EMC and electromagnetic interference EMI is greatly affected by the wiring and has to be checked for each installation A WARNING The supply to the various consumers e g battery has to be protected adequately by fuses consult wiring diagram Using fuses too large may result in damage to electric equipment Under no circumstances route consumers cables e g bat tery side by side with ignition cable Induction could cause problems CAUTION Anexcess voltage protection has to be realized by the aircraft manufacturer in accordance to effective regulations A WARNING The certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer Effectivity 912 Series page 107 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL WARNING Do not bend
34. engine type 912 for safety and durability to the standards of aviation The furnishing of proof in accordance to the latest FAR or EASA has to be conducted by the aircraft manufacturer airbox external alternator engine suspension frame vacuum pump feasible on version 2 and version 4 only drive for rev counter hour meter oil cooler with connections coolant radiator coolant overflow bottle 104633 Effectivitv 912 Series page 22 Edition 1 Rev 1 May 01 2009 104633 BRP Powertrain INSTALLATION MANUAL 9 Preparations for engine installation CAUTION stated directives are measures to pay CAUTION to at engine installation to prevent any accidents and engine damage 9 1 Transport The engine to be lifted by two hooks or straps around the middle A of the intake manifolds See chapter engine views numbering of cylinders and definition of main axes 9 2 State of delivery The engine could be attached with to steel angles anchored on a timber plate CAUTION The attachment screws are only for transport and must not be used in the aircraft 9 3 Engine preservation The engine is preserved at BRP Powertrain thus warranting proper protection against corrosion for at least 12 month after date of delivery from BRP Powertrain This warranty is subject to the following conditions the engine has to be stored in the packing as supplied by BRP Powertrain the covers on v
35. f BRP Powertrain See section 16 These lines must not be routed into the slipstream or down the firewall Pressure differences between intake pressure and pressure in the carburetor chambers may lead to engine malfunction due to incorrect fuel supply Connecting nipple 2 for leakage line outside dia 6 mm 1 4 slip on length max 17 mm 11 16 Effectivity 912 Series page 92 Edition 1 Rev 1 May 01 2009 d04638 104638 BRP Powertrain INSTALLATION MANUAL 08644 Effectivitv 912 Series page 93 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL 15 2 Connections for Bowden cable actuation and limit load See Fig 2 3 4 60 and 61 centre position of carburetor socket P1 of the respective carburetor NOTE All dimensions to point of reference P limit load on point of reference P2 CAUTION The specified limit loads must never be exceeded 00538 coordinates P1 mm max allowable forces imit Ioas carburetor for in x y and z axis max allowable bending moments cylinder 1 3 in x y and z axis connection 1 for air filter or intake silencer outside dia 50 mm 2 in slip on length 12 mm 47 in connection for throttle actuation 2 connection on throttle lever set screw M 5x12 tightening torque 4 Nm 35 in lb suitable for 1 5 mm 06 in steel wire action travel 65 mm 2 7 actuating force min 1 5 N
36. g 69 70 type electronic full wave rectifier regulator effective voltage 14 0 3 V from 1000 250 r p m current limit max 22 A max permissible component temperature 80 C 176 F measured in area 1 weight see section 8 NOTE The performance specifications are given for optimal cooled components If necessary use a separate heat sink for the rectifier regulator d04059 Effectivity 912 Series page 110 Edition 1 Rev 0 May 01 2007 904640 BRP Powertrain INSTALLATION MANUAL Description of connections G yellow from generator red to battery positive terminal B battery positive terminal L warning lamp circuit control or field circuit 4 92 3 62 1 A Eo 4e H mitt EN n LLLI 5 106 4 18 in Fig 69 08631 Requirements for flawless operation of the rectifier regulator body of regulator must be grounded with no restance allowed the rectifier regulator has to be protected by a slow blowing 25A fuse wire size of the main circuit of at least 2 5 mm 14 AWG capacitor Fig 67 Pos 25 of at least 22 000 uF 25 V is necessary to protect the correct function of regulator and to flatten voltage The regulator is not designed to store any electrical charge If for any reason the battery or bus system is disconnected from the regulator while the engine is running i e the master switch is shut
37. gth max 15 mm 9 16 CAUTION hoses have to be fixed with appropriate clamps to prevent loss E g with spring type clamps as used already for the water tubes between water pump and cylinder Good field experi ence has been made with this type of clamps See therefore also SI 912 020 Running modifications latest issue The aircraft manufacturer has to carry out the check of coolant level in the expansion tank and note it in the daily inspection section of his flight manual according latest issue of Operators Manual ROTAX 912 It is recommended to make adequate precautions for accomplishment of these inspections e g a flap or panel on the cowling or a warning instrument in the cockpit for low coolant level Effectivity 912 Series page 55 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL 200 10 mm Effectivity 912 Series Edition 1 Rev 0 page 56 May 01 2007 904054 104635 BRP Powertrain INSTALLATION MANUAL 12 9 General directives for the cooling svstem See Fig 29 BRP Powertrain offers essential parts of the cooling svstem for this engine such as radiator etc A WARNING Certification to the latest requirements to FAR or EASA has to be conducted the aircraft manufacturer 1
38. ical data See Fig 80 direction of rotation of the prop flange counter clockwise looking towards face of flange attachment of propeller on prop shaft flange P C D 75 mm 2 95 6 bolt holes of 8 mm 32 in dia P C D 80 mm 3 15 6 bolt holes of 11 5 mm 45 in dia P C D 101 6 mm 4 6 bolt holes of 13 mm 51 in dia hub diameter 47 mm 1 85 in ratio of gear reduction 2 2727 50 Teeth 22 T 2 4286 51 T 21 T max torque ROTAX 912 UL A for i 2 2727 238 Nm 176 ft lb at propeller ROTAX 912 UL A for i 2 4286 255 Nm 188 at propeller ROTAX 912 ULS S for i 2 4286 315 Nm 232 ft lb at propeller max moment of inertia normal between 1500 kgem 3 559 Ib ft and 6000 14 238 Ib ft max moment of inertia on propeller 6000 14 238 Ib ft 2 max permitted static out of balance on a prop max 0 5 gm 043 Ib in max extension of the propeller shaft 120 mm 4 72 in CAUTION modification of propeller shaft permitted page 121 May 01 2009 BRP Rotax INSTALLATION MANUAL In the course of certification a vibration analysis of the whole system engine suspension propeller etc should be done If there are no limits found in the technical literature a max of 0 1 IPS inches per second at 5000 rpm can be assumed 120 mm 4 72 in 46 gt
39. ications are only allowed after consent by the engine manufacturer CAUTION Spare parts must meet with the requirements defined by the engine manufacturer This is only warranted by use of GENU INE ROTAX spare parts and or accessories see Illustrated Parts Catalog They are available only at the authorized ROTAX Distribution and Service Centers The use of anything other than genuine ROTAX spare parts and or accessories will render any warranty relating to this engine null and void see Warranty Conditions A WARNING Engine and gear box are delivered in dry conditions without oil Before putting engine in operation it must be filled with oil Use only oil as specified consult Operators Manual and SI 912 016 Selection of suitable operating fluids current issue Effectivity 912 Series page 13 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL A WARNING Exclusively use tools and supplementary materials as listed in the Illustrated Parts Catalog A WARNING This Manual for engine installation is only part of the Technical Documentation and will be supplemented by the respective Operators Manual Maintenance Manual and Spare Parts List Pay attention to references to other documentation found in various parts of this Manual 4 4 Technical documentation The information given in the Installation Manual Operators Manual Maintenance Manual Line Maintenance Maintenance Manual Heavy Maintenanc
40. ide outside dia 60 mm 2 3 8 slip on length max 25 mm 1 B CAUTION Utilize the full slip on length on all connection Secure hoses by suitable spring type clamp or screw clamp 16 2 1 Requirements on the intake air ducting max length of ducting 500 mm 20 in min inside dia at least outside dia of the intake socket on airbox min mean bending radius 100 mm 4 High engine performance needs air temperature as low as possible at air intake Therefore the air filter should be located in a recess of the engine cowling or separated from warm air by baffles such that fresh air can be aspirated 16 2 2 Airfilter CAUTION minimum flow rate of 6 23 m min 220 cfm has to be warranted for all conditions The pressure loss must not exceed 2 hPa WARNING Use only filter elements which will not tend to restrict the flow when in contact with water BRP Powertrain offers an air filter as described below Effectivity 912 Series page 100 Edition 1 Rev 1 May 01 2009 d04639 d04058 BRP Rotax INSTALLATION MANUAL WARNING The certification to the latest requirement such as FAR and EASA has to be conducted by the aircraft manu facturer The following points should assist the aircraft manufacturer at the choice of a suitable filter four fold cotton fabric surface covered with metal screen total filter area at least 1400 cm 220 in amin flow rate of 6
41. ign 07600 With suspension on the 4 top lugs L3 R3 L4 and R4 only the tilting moment due to the pull of the propeller will be avoided while if attached on the bottom lugs only the moment of tilting has to be taken care of accordingly A certified engine suspension frame has been developed by BRP Powertrain especially for the magneto side engine at tachment to the fireproof bulk head If the engine suspension frame supplied by BRP Powertrain is not used the engine installation must by ground run tested to the specified loads and for vibration behaviour Certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer The rubber mounts to neutralize vibrations and all the engine suspension components not in the supply volume must be ground run tested to the specified loads and for vibration behaviour Certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer The engine suspension has to be designed to prevent any excessive engine movement and to minimize noise emission and vibration on air frame side See also SL 912 010 Identifying abnormal vibrations on aircrafts latest issue Effectivity 912 Series Edition 1 Rev 1 page 38 May 01 2009 d04634 BRP Rotax INSTALLATION MANUAL 11 2 operating limits See Fig 14 exhaust gas temperature EGT both ignition circuits active nominal approx 800
42. il pump via oil cooler ata max distance of 100 mm 4 in from pump inlet 2 At take off performance the indicated vacuum 3 must not be more than 0 3 bar 4 35 psi otherwise the oil hose 1 could collapse and thus blocking the oil supply to the engine Fig 41 A WARNING The vacuum 3 must be verified over the total range of engine operation Specially on cold oil temperature the flow resistance increases so that not enough oil can flow on suction side x 0 1 bar max 0 3 bar 4 35 psi below atmospheric pressure Effectivity 912 Series page 69 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL 13 3 2 Measuring of the pressure in the crankcase Measure of the mean crankcase pressure at full load blow by gas pressure responsible for proper oil return from crankcase to oil tank A pressure indicator 4 pressure gauge with incorporated viscous damper may be fitted instead of the magnetic plug 5 or the crankshaft locking screw 6 see Fig 42 NOTE The connecting thread is M12x1 5 metric for the magnetic plug and M8 for the crankshaft locking screw use always new gasket The pressure in the crankcase at full load must not exceed the prevailing ambient pressure by more than 0 45 bar 6 53 psi at 90 C 194 F oil temperature If both pressure readings are within the specified limits under all operating conditions the lubrication circuit
43. ing of these instructions will not eliminate a hazard the understanding and application of the information herein will promote the proper installation and use of the engine The information and components svstem descriptions contained in this Installation Manual are correct at the time of publication BRP Powertrain however maintains policy of continuous improvement of its products without imposing upon itself any obligation to install them on its products previously manufactured BRP Powertrain reserves the right at any time to discontinue or change specifications designs features models or equipment without incurring obligation The illustrations in this Installation Manual show the typical construction They may not represent in full detail or the exact shape of the parts which have the same or similar function Specifications are given in the SI metric system with the USA equivalent in parenthesis Where precise accuracy is not required some conversions are rounded off for easier use 4 1 Repeating symbols This Manual uses the following symbols to emphasize particular information These indications are important and must be respected A WARNING Identifies an instruction which if not followed may cause serious injury including the possibility of death CAUTION Denotes an instruction which if not followed may se verely damage the engine or other component NOTE Indicates supplementary information which m
44. l automatically exclude any liability of the manufacturer for sequential damage Effectivity 912 Series page 12 Edition 1 Rev 1 May 01 2009 d04632 104632 BRP Powertrain INSTALLATION MANUAL In addition to observing the instructions our Manual general safety and accident preventative measures legal regulations and regulations of any aeronautical authority must be observed Where differences exist between this Manual and regulations provided by any authority the more stringent regulation should be applied This engine may be equipped with an other than the ORIGINAL ROTAX vacuum pump The safety warning accompanying the air pump must be given to the owner operator of the aircraft into which the air pump is installed 4 3 Instruction Engines require instructions regarding their application use operation mainte nance and repair Technical documentation and directions are useful and necessary comple mentary elements for personal instruction but can by no means substitute theoretical and practical instructions These instructions should cover explanation of the technical context advice for operation maintenance use and operational safety of the engine All technical directives relevant for safety are especially emphasized Pass on safety instructions to other users without fail This engine must only be operated with accessories supplied recommended released by BRP Powertrain Modif
45. les A and B plug connection for ignition switch integrated generator external regulator rectifier with plug connections electric starter starter relay with plug connection external alternator with connections electric rev counter Effectivity 912 Series Edition 1 Rev 1 page 108 May 01 2009 d04640 BRP Powertrain INSTALLATION MANUAL 14 capacitor 15 2 ignition switches 16 master switch 17 starter switch 18 control lamp 19 battery relay 20 battery 21 bus bar 22 capacitor 23 plug connection for trigger coil assy 24 trigger coil assy tachometer 25 electrical fuel pump 26 starting equipment at the electronic modules 1 9 Wiring symbols to DIN 40712 40713 40716 and 40719 08639 Effectivity 912 Series page 109 Edition 1 Rev 1 May 01 2009 104640 BRP Rotax INSTALLATION MANUAL 17 3 Technical data and connection of the electric components 17 3 1 Integrated generator See Fig 68 Feeding wires 1 from the generator to rectifier regulator on left side of ignition housing see Fig 68 2 flexible cables 1 5 yellow in shielding metal braid length approx 660 mm 26 in starting from ignition housing with on each plug socket 6 3 x 0 8 to DIN 46247 NOTE approx 250W AC output at 5800 r p m For DC output in connection with rectifier regulator see section 17 3 2 17 3 2 Rectifier regulator See Fi
46. ll 4 cylinders and positioned under the engine is favourable NOTE Equal length of pipes from the cylinder to muffler is recom mended for better tuning Distribution of the exhaust gases into 2 separate systems is not recom mended Single mufflers on either side cause power loss and increased noise emission The 4 ball joints must be used to avoid damage due to vibration Be aware that locked up stresses cause cracks Attachment of exhaust bends by springs Springs to be secured with safety wire to prevent FOD All ball joints have to be greased regularly with heat resistant lubricant e g LOCTITE ANTISEIZE to avoid gripping and seizing of the joints B CAUTION Vibrations due to improper installation and maintenance is the most common reason for damage of the exhaust system d04634 Effectivity 912 Series page 42 Edition 1 Rev 1 May 01 2009 104635 BRP Powertrain INSTALLATION MANUAL 12 Cooling svstem 12 1 Description of the svstem See Fig 21 The cooling svstem of the ROTAX 912 is designed for liquid cooling of the cvlinder heads and ram air cooling of the cvlinders The cooling svstem of the cvlinder heads is a closed circuit with an expansion tank and overflow bottle The coolant flow is forced by a water pump driven from the camshaft from the radiator to the cvlinder heads From the top of the cvlinder heads the coolant passes on to the expansion tank 1 Since the standard location of the radia
47. llation only Before engine operation remove these pro tections d04052 Effectivity 912 Series page 32 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL 10 Engine suspension and position CAUTION Atinstallation of engine be aware of engine weight and assure careful handling The engine suspension is determined essentially by the aircraft design Twelve attachment points are provided on the engine 8 on engine and 4 on engine frame The engine can be supplied with a well tried and certified suspension frame for attachment on the fire proof bulk head The airbox is supported on this frame too The installation into the aircraft is as generally practised by captive rubber mounts which ensure also to balance out vibrations and sound from engine to aircraft frame WARNING If the engine suspension frame supplied by BRP Powertrain is not used or if modified certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer It is recommended to use the ROTAX engine suspension frame and the 4 stated attachment points R2 L2 and 13 A WARNING At least 4 of the given anchorage points must be used in a side symmetrical pattern of the left L and right R side d04634 Effectivity 912 Series page 33 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL 10 1 Definition of attachment points See Fig 8 08318 JA V
48. max 17 mm 11 16 CAUTION Utilize the total slip on length on all joints Secure hose by suitable screw clamps or crimp connection A WARNING Protective covering to be utilized for transport and at engine installation only If connection for pressure reading is not employed it has to suitably plugged New style compensating tubes have plugged this connection by a screw M3 5x6 2 CAUTION Flawless operation of the indicating instrument needs the installations of a water trap between engine and instrument for the fuel condensate 904641 Effectivity 912 Series page 131 Edition 1 Rev 1 May 01 2009 BRP Powertrain INSTALLATION MANUAL 21 6 Air temperature in the airbox optional See Fig 93 To take air temperature readings in the airbox a connection is provided This connection is closed on the standard engine by a plug screw connection thread M6 thread length approx 9 mm 3 8 08647 E 8 Effectivity 912 Series page 132 Edition 1 Rev 1 May 01 2009
49. occur with cylinder head temperatures higher than 150 C 300 F for ROTAX 912 UL A F and 135 C 275 F for ROTAX 912 ULS S It does not require pressure to maintain its boiling point Due to a lower thermal conductivity the engine temperature will typically run about 5 10 C 41 50 F higher with waterless coolant Permanent monitoring of cylinder head temperature is necessary Additional monitoring of the actual coolant temperature is possible but not necessary for waterless coolant Effectivity 912 Series page 49 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL NOTE When using EVANS NPGR NPG or added pure ethylene glycol as a coolant note that these fluids have a flammability rating 1 classification LOW at a scale from 0 to 4 The mentioned coolants are complying according to their material safety data sheet with a flammability classification which has only low danger and a low risk of flammability To date no cases in engine operation or flight operation laboratory conditions or from the field were reported which show unsafe conditions of ROTAX aircraft engines in combination with the relevant coolants Marking of the coolant to be used CAUTION Thecoolantto be used and its concentration percentage water rate must be communicated to the owner in the correct form Waterless coolant must not mix with water as otherwise it will lose the advantages of a high boilling point
50. off the capacitor will safely absorb and dissipate the electrical charge produced by the generator Otherwise the regulator would be damaged CAUTION The voltage difference between battery and terminal C of regulator should be less than 0 2 V Use cables in this area as short as possible and with adequate cross section CAUTION Never sever connection between terminal C and B of regulator e g by removal of a fuse while the engine is running Overvoltage and regulator damage can occur Effectivity 912 Series page 111 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL During engine stop break circuit between battery and terminal C to avoid discharge of battery see Fig 67 NOTE A charge indicating lamp 3W 12V Fig 67 pos 18 may be fitted on the instrument panel Current CAUTION graph current over engine speed has been deter mined and is valid only at the following conditions ambient temperature 20 C 68 F L A permanent 13 5 V tolerance 5 02500 0 1000 2000 3000 4000 5000 6000 1 min 17 3 3 Electronic modules 17 3 4 Ignition switches MAG switch See Fig 4 and 71 Ambient temp for the electronic modules 1 max 80 C 176 F See Fig 71 72 and 73 type two separate suitable on off switches Fig 67 pos 15 switching voltage min 250 V switching current min 0 5
51. ompressor outlet regulator so thatthe airline pressure is between 0 4 6 psi and 1 bar 15 psi Do not exceed 1 bar 15 psi NOTE Oil tank cover is not designed to hold pressure Some air will escape A WARNING not remove oil tank or cover before ensuring that air pressure has been completely released from the tank The pressure in the oil tank has to be maintained during the following step B CAUTION Itis possible to empty the oil tank and as a result introduce more air into the oil system Pay attention to the oil level and fill tank as required Turnthe engine by hand in direction of normal rotation until the first pressure indication on the oil pressure gauge Normally this will take approx 20 turns Depending on installation it may take up to 60 turns CAUTION Donotusestarterforthis purpose Fit propeller and use itto turn engine Effectivity 912 Series page 78 Edition 1 Rev 0 May 01 2007 d04055 d04637 BRP Powertrain INSTALLATION MANUAL 14 4 Connecting dimensions location of joints and directives for installa tion 14 4 1 fuel manifold See Fig 2 3 4 55 position of 24 axis of the fuel manifold NOTE Dimensions always from point of reference P return line to tank 5 outside dia 7 mm 28 in slip on length max 17 mm 67 in pressure gauge connection 6 outside dia 6 mm 24 in slip on length max 17 mm 67 in fuel pre
52. on If any passages of the Manual are not completely understood or in case of questions please contact an authorized Distribution or Service Center for ROTAX engines BRP Powertrain GmbH amp KG hereinafter BRP Powertrain wish you much pleasure and satisfaction flying your aircraft powered by this ROTAX engine 3 1 Remarks This Installation Manual is to acquaint the owner user of this aircraft engine with basic installation instructions and safety information For more detailed information on operation maintenance safety or flight consult the documentation provided by the aircraft manufacturer and dealer For further information on maintenance and spare part service contact the nearest ROTAX distributor see section 3 3 3 2 Engine serial number On all enquiries or spare parts orders always indicate the engine serial number as the manufacturer makes modifications to the engine for further development The engine serial number is on the top of the crankcase magneto side 3 3 ROTAX Authorized Distributors for Aircraft Engines See latest Operators Manual or in the Internet at the official Homepage www rotax aircraft engines com 904632 Effectivity 912 Series page 9 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 1 Rev 0 page 10 May 01 2007 d04051 104632 BRP Powertrain INSTALLATION MANUAL 4 Safetv Although the mere read
53. on 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL 21 2 Sensor for oil temperature See Fig 86 and 87 location oil pump housing marking 2 marked with TO temperature oil on oil pump flange CAUTION To avoid any mix up with indication wiring mark this particular cable also with TO x axis y axis 2 axis mm mm mm El support position of the temperature sensor 1 on the oil pump flange Axes 04869 connection of sensor wiring spade terminal 6 3 x 0 8 to DIN 46247 grounding via engine block graph of sensor resistance over temperature CAUTION The graph resistance over temperature has been determined 1 effective at the following conditions only ambient temperature 20 C 68 F tolerance 10 BRP Powertrain offers non certified temperature indicating instrument Refer to Illustrated Parts Catalog latest issue A WARNING Certification to the latest requirements such as FAR of EASA has to be conducted by the aircraft manufacturer Q 1200 1000 800 600 aan 00227 400 200 20 40 60 80 100 120 140 904641 Effectivity 912 Series page 128 Edition 1 Rev 1 May 01 2009 904641 BRP Powertrain INSTALLATION MANUAL 21 3 Oilpressuresensor See Fig 88 and 89 location oil pump housing wiring connection fo
54. r and connecting lines min 0 8 US gal depending on the respective installation Volume of oil tank up to the MIN mark approx 2 5 0 66 US gal up to the MAX mark approx 3 01 0 8 US gal Perform oil level check and add oil if necessary page 77 May 01 2009 BRP Rotax INSTALLATION MANUAL 13 10 Purging of lubrication system See Fig 51 Verify that oil tank connections are connected correctly and secured and that the oil cooler if fitted is in the suction line 1 between the oil tank and the oil pump inlet Verify that the oil tank is filled up to the maximum level to the top of the flat portion of the dipstick Additional oil up to 0 5 litre may be added to the tank for the purpose of this procedure CAUTION Incorrectly connected oil lines to the oil tank or to the engine will result in severe engine damage Disconnect oil line 2 at the oil tank connection Place the free end 3 of the return oil line into a suitable container 4 below the engine Plug open connection 5 at the oil tank with suitable air tight cap See Fig 51 Remove the spark plug connectors For easier rotation of engine remove one spark plug from each cylinder CAUTION Prevent entering of foreign substance through spark plug hole Using a compressed air line pressurize the oil tank through its breather connection 6 on the neck of the tank Adjust the c
55. r instrument The sensor cable is approx 3 m long and has 3 leads The Black lead is not to be connected and has no function The Red lead from the sensor has to be connected to the positive bus via a fuse or circuit breaker The White lead output signal has to be connected directly to the instrument See also the relevant instructions of the instrument supplier aircraft manufacturer for correct connection and wiring NOTE The sensor cable can be modified in its length according to the installation situation e g shortened or extended For extension an appropriate commercially available cable can be used A resistance cable or similar is not necessary wire gauge stranded wire 0 5 mm AWG 20 cable length 3m 118 in operating temperature range 40 40 F max 125 C 257 F grounding via engine block airframe ground output signal In contrary to the oil pressure sensor offered up to now which was providing the signal on the basis of a sensor resistance variation the new oil pressure sensor 1 operates on basis of a current variation This has to be taken into account for the selection of the appropriate cockpit instrument CAUTION The graph current over pressure has been determined and is Effectivity 912 Series Edition 1 Rev 1 effective at the following conditions only see fig 89 ambient temperature 20 C 68 F tolerance max 3 tightening torque 15 Nm 98 in lb
56. s to be conducted by the aircraft manufacturer CAUTION changes on the air intake system e g modification on the airbox etc can affect the flow rate in the air intake system and the fuel mixture ratio In the course of certification the fuel mixture process must be proofed by a CO measurement CO Measurement CO Emission min 3 0 CO wide open throttle WOT an rpm of min 5200 1 min needs to be achieved Measurement in original configuration of aircraft e g with installed cowling Measured on each single cylinder Measuring point is the same as the EGT measurement See section Exhaust system Effectivity 912 Series page 99 Edition 1 Rev 1 May 01 2009 BRP Powertrain INSTALLATION MANUAL 16 2 Requirements on the air intake system A WARNING Carb icing is a common reason for engine trouble No imple ments are included in the supply volume for preheating of the intake air If an airbox of not ROTAX origin is used provisions for preheating the intake air have to be made to prevent formation of ice in the intake system Preheating of the intake air will result in performance loss because of the lower air density A WARNING AII items of the air intake have to be secured against loss A WARNING The certification to the latest requirements such as FAR and EASA has to be conducted by the aircraft manufacturer Air intake socket 1 for fresh air or pre heated air intake s
57. should be working suffi ciently WARNING Ifthe readings exceed the pressure limits then the flow resistance of the oil from oil sump to oil tank contami nation restrictions of cross section etc is too high This condition is unsafe and must be rectified without delay max 0 45 bar 6 53 psi above at mospheric pressure 08324 Effectivity 912 Series page 70 Edition 1 Rev 0 May 01 2007 104055 BRP Rotax INSTALLATION MANUAL Oil pump inlet nipple 2 outside dia 13 2 mm 0 52 in slip on length max 21 mm 0 83 in 00226 Oil pump inlet 3 thread 3 4 16 UNF AN 8 Tightening torque of inlet line 25 Nm 18 5 ft Ib 09123 8 3 Effectivity 912 Series page 73 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL Oil return CAUTION The engine designisfora conventional non aerobatic fixed wing tractor or pusher type configuration with the oil return port in the optimum position With this consideration the engine is properly lubricated in all flight profiles Aircraft that are not conventional e g airship gyrocopters dive brake equipped aircraft etc that require engine load in steeply incline and decline angles see also sec 8 1 point 12 may require special lubrication considerations According to propeller configuration and oil sys
58. ssure switch connection 9 10 thread length max 9 mm 35 Tightening torque 15 Nm 135 in Ib and Loctite 221 CAUTION Atloosening or tightening of the banjo bolt 7 tighten ing torque 10 Nm 90 in Ib support the fuel manifold appropriately NOTE The connection nipple 5 is furnished with an orifice Effectivity 912 Series Edition 1 Rev 1 8 0 35 mm 0 014 in essential for operation of the fuel system If the pressure gauge connection 6 is not used anda hose nipple 10 installed the banjo bolt assy 11 marked with a colour dot or marked FUEL is fur nished with an orifice 12 0 35 mm 0 014 in This is essential for operation of the fuel system as it prevents a loss in fuel pressure coordinates mm X axis Z axis clamp block page 87 May 01 2009 fuel pressure sensor connection to carburetor BRP Rotax INSTALLATION MANUAL to fuel tank gt v 09192 09139 Y 14 4 2 Fuel pressure control See Fig 56 and 57 hose connection on fuel pump 1 inlet by slip on joint See fig 56 Fuel intake connection 9 outside dia 9 mm 35 in slip on length max 24 mm 95 in Fuel outlet connection 10 outside dia 6 mm 24 in slip on length max 24 mm 95 in CAUTION Ensure at installation of the supply line to fuel pump that no additional moments or load will rest on the pump
59. tem layout choose the appropriate connection for the oil return line Position 1 for tractor or position 2 for pusher configuration and connector options 1 2 and 5 See Fig 47 Option 1 connection with slip on connection 1 hose nipple 3 10 DIN 7642 DUISIdO GIA issues 13 5 mm 53 in Slip on length max 24 mm max 94 in Tightening torque of banjo bolt 4 M16x1 5x28 30 Nm 22 ft Ib Option 2 and 3 connection with screw connection 2 or 5 connection with screw connection 2 thread 3 4 16 UNF AN 8 Tightening torque of oil return line 25 Nm 18 5 ft Ib Tightening torque of screw connection 2 M16x1 5 25 Nm 18 5 ft lb connection with screw connection 5 3 4 16 UNF 8 Tigiienmng tor torque of oll return line mnc 25 Nm 18 5 ft Ib AGT Aw Tightening torque of banjo bolt 4 M16x1 5x28 30 Nm 22 ft lb DIO sta AT IY ae P 4 Druckpropeller Zugpropeller pusher config tractor config Fig 47 re 5 8 2 B 08634 104636 Effectivitv 912 Series page 74 Edition 1 Rev 1 Mav 01 2009 104636 Effectivitv 912 Series Edition 1 Rev 1 13 7 13 8 13 9 BRP Powertrain INSTA
60. tion b Maximum cylinder head temperature and coolant exit temperature is below operating limit For operating with conventional coolant it is necessary to monitoring constantly cylinder head temperature and coolant exit temperature NOTE For detection of possible indication error an additional monitor ing of the cylinder head temperature is necessary which shows an exceedingin case of coolant loss The aircraft manufacturer has the option of converting the coolant temperature and the cylinder head temperature to an aircraft specific cylinder head tem perature This is possible by calculating the difference between the head material and the coolant temperature This is done by following the flight test procedure on page 53 Effectivity 912 Series page 52 Edition 1 Rev 0 May 01 2007 04054 104635 BRP Powertrain INSTALLATION MANUAL Expansion tank to overflow bottle hose Hose connecting expansion tank to overflow bottle must be rated for vacuum suction for min 125 C 257 F E g it must be strong enough to withstand high heat and suction during the cooling down period A WARNING A soft walled hose is not suitable as it can collapse and cause coolant system failure 12 7 Size and position of connections See Fig 26 27 28 expansion tank 1 with radiator cap 2 to radiator 3 outside dia 25 mm 1 slip on length max 22 mm 7 8 to overflow bottle 4 outside dia 8 mm 3 8 slip on len
61. tor 2 is below engine level the expansion tank located on top of the engine allows for coolant expansion The expansion tank is closed by a pressure cap 3 with pressure relief valve and return valve At temperature rise and expansion of the coolant the pressure relief valve opens and the coolant will flow via a hose at atmospheric pressure to the transparent overflow bottle 4 When cooling down the coolant will be sucked back into the cooling circuit 09152 The shape size and location of one or more radiators depend mainly on the space available On good installation in the airplane the radiator by BRP Powertrain optional has enough cooling capacity to keep within the normal specified operating limits Also the flow of coolant liquid through the radiator is not restricted and the tube size is sufficient Effectivity 912 Series page 47 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL 12 2 Operating Limits Using conventional coolant Coolant temperature coolant exit temperature de de 120 C 248 F Cylinder head temperature ROTAX 912 AD iii ke 150 300 ROTAX 912 15 6 MAK 135 275 F Permanent monitoring of coolant temperature and cylinder head temperature is necessary Using waterless coolant Cylinder head temperature ROTAX 912 UL A F 150 C 300 F ROTAX 912
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